Repeat Lift System Failure - 2017 Rockwood HW296

[srpender]

Anyone having any issues with their power lift (to lift & lower the hard top) "crushing" the mounting bracket? My unit has crushed two within 12 months. Comments & suggestions are welcomed.

[backpacker3]

Don't really know what to say after seeing your picture. Never seen or heard of such a failure. Have you taken it to dealer and did they say anything? Does Forest River have any comments?

[OttieJB]

I have the same year but a different model—HW276. I’ve noticed that the mounting bracket starts to bounce/flex near the end of the roof lift cycle. With that said, I believe your roof is of the same construction as mine, just longer therefore heavier. Sounds like FR needs to beef up the brackets on the HW296 possibly assuming your cable or lift system isn’t binding in some way upon lifting the roof.

[flyerdp]

That's insane!

The load the motor is pulling must be to too much for that frame?

I'll assume you have lubed the under carriage tubes with NLGI 2 and the 4 lift pillars with 30 weight oil as recommended?

If the dealer can't fix I would suggest better bracing for that thing?! Some extra steel straps maybe.

[srpender]

Thanks everyone. Power winch identified the cause as not stopping the lift system when it fully up or fully down. Likely limit switches incorrectly set. Hard lesson.

[Cigar Mike]

Have set your start and stop points on the winch?

[Mike91]

Originally Posted by srpender

Thanks everyone. Power winch identified the cause as not stopping the lift system when it fully up or fully down. Likely limit switches incorrectly set. Hard lesson.

Well wouldn't you have to break your roof height indicator cable before hitting the High limit switch? Seems if the limit switch didn't take the motor out, you'd have a lot more damage to your tent and maybe roof and lifter posts?

If you're letting it down, you'd just have slack in your cable if you went to far.

Doesn't make sense to me.

[srpender]

Cigar Mike ... paid the selling dealer, Campers Inn (Kings Mountain, NC) to do just that after they replaced the crushed mounting plate (was delivered with a crushed mounting plate).

Mike91 ... the top "powers down" so the cable is under a load coming down. It will continue if the stop is not set correctly

Thanks everyone for the comments. I have a new mounting plate on the way and a competent independent serviceman doing the replacement and setting the limit switches for both the "up" and "down" motion on the system.

[OttieJB]

Originally Posted by srpender

Cigar Mike ... paid the selling dealer, Campers Inn (Kings Mountain, NC) to do just that after they replaced the crushed mounting plate (was delivered with a crushed mounting plate).



Mike91 ... the top "powers down" so the cable is under a load coming down. It will continue if the stop is not set correctly



Thanks everyone for the comments. I have a new mounting plate on the way and a competent independent serviceman doing the replacement and setting the limit switches for both the "up" and "down" motion on the system.

I think Mike91 is referring to this cable (red) in the picture. Even without limit switches set, you release the main winch switch when it’s taut.

[srpender]

Thanks for your comment OttieJB. The failure occurred in the "down" mode, as the individual did NOT release the switch when the top was fully down, but instead "tightened up" the down position ... bummer, since the individual was not me.

[OttieJB]

No problem.

[Cigar Mike]

Most likely occurred going up. When I put mine down, once it's down it just puts slack in the cable. Unless it pinched the cable on the drum there shouldn't be any pull on the cable.

If anyone else needs to set the limit switches. It is very simple. They are easily adjusted using an Allen wrench. Tube has how video.

[93rdvet]

Originally Posted by srpender

Anyone having any issues with their power lift (to lift & lower the hard top) "crushing" the mounting bracket? My unit has crushed two within 12 months. Comments & suggestions are welcomed.

Yes, I have a HW276 and it did the same thing. I had to call FR because the local dealer would not fix it. Long story short, they were told to fix it. Did an OK job but I had to complete it with another brace. The original bracket is not a good design as you can see a lot of movement when operating the power lift. I was told the roof is to heavy for the system. Works fine now

[srpender]

Thanks for your comment 93rdvet & thanks for confirming that additional braces make a nice design & performance improvement. I was planning on adding a "double H" shaped brace once the old bracket is removed and the new one installed. I didn't even contact the dealer since this is the second bracket to fail for me ... my independent RV Repair fella' is most agreeable once the part arrives from Forest River. Take good care.

[93rdvet]

Dealer welded supports on the sides of the bracket. This helped a little but the center of the bracket had some movement. I added a center brace that eliminated the movement. Seems to work, I will continue to monitor and upgrade as needed. I added a photo, hope it comes through.

[srpender]

Hello 93rdvet ... thanks for sharing that photo ... nice job. Take good care.

[Chris H]

I have a 2018 HW296 that once the top is lifted to correct position, it slips back down and the guide wire is very loose. I read somewhere that the clutch needs to be adjusted. Any thoughts would be appreciated.

[Mike91]

Originally Posted by OttieJB

I think Mike91 is referring to this cable (red) in the picture. Even without limit switches set, you release the main winch switch when it’s taut.Attachment 207976

I was talking about that guide wire but also if the winch continued after the roof was down, you'd get extra slack. The limit switch would prevent it from having to much slack and unrolling.

I'd say the weight of the roof, when coming down, pulled the winch down and the support plate down into the mounting hole in the tongue. I can't see it being because to much slack, just the weight of the roof pulling the winch down (until the roof rested on the walls) where the plate failed from not being strong enough.

Perhaps going slowly when raising or lowering the roof, would be less stressful on the mount instead of a continuous run.

Hopefully FR will or already has done a structural update to this winch mount so that it doesn't fail on everyone who owns this floorplan.

[Mike91]

Originally Posted by Chris H

I have a 2018 HW296 that once the top is lifted to correct position, it slips back down and the guide wire is very loose. I read somewhere that the clutch needs to be adjusted. Any thoughts would be appreciated.

I would have the dealer do this and it might be covered under warranty. Doesn't the lift system have a life time warranty and the roof a 5 year warranty. I would expect the winch and motor to be covered as it's part of the lift system on these models.

[srpender]

I would agree with the recommendation to determine if this is covered under warranty and have a dealer do the work. The downside of a dealer is that is may take months to get into their schedule.

However, your reading is spot on. On page 11 of the most recent manual from PowerWinch, your specific concern is addressed. If you are comfortable doing this yourself, it will be much quicker than waiting on a dealer.